TECHNICAL FIELD

The present invention relates to a solid state fermentation (SSF) system. More particularly  the invention relates to a system for solid-state fermentation.

BACKGROUND

Generally  solid state fermentation is used to cultivate microorganisms for separation of microorganisms themselves or the metabolic product or a microbial altered substrate e.g. in the food-processing industry. The SSF is defined as growth of microorganisms  usually fungi on solid substrates in a defined gas phase  but in absence or near absence of free water phase. Current decade has witnessed an unprecedented spurt in SSF for the development of bioprocesses such as bioremediation and biodegradation of hazardous compounds  biological detoxification of agro-industrial residues  biotransformation of crops and crop-residues for nutritional enrichment  biopulping and production of value-added products such as biologically active secondary metabolites   including antibiotics  alkaloids  plant growth factors  enzymes  organic acids  biosurfactants  aroma compounds etc.

SSF was already used for the production of fermented food  of enzyme products or of edible mushrooms in certain territories of the Orient  Asia and Africa in the Ancient World. However  many institutes and firms recently show their interest in the SSF  because there are certain advantages compared to the submerged fermentation. Such advantages compared to the submerged fermentation are possibility of an effective production of secondary metabolites such as enzymes  aromatic substances and coloring substances as well as pharmaceutically active substances  possibility of production of microorganisms in the form of biological agents in agricultural pesticides or elimination of toxins or other detrimental substances from food stuff or enrichment of proteins or vitamins of this stuff.

However  the application and utilization of agricultural and other domestic wastes through fermentation processes and enzymatic conversion are limited due to their low volume systems. Therefore  a good and reproducible solid state fermentation (SSF) is needed. The SSF fermenters as available at present are relatively limited in the market worldwide. Generally  three types of fermenters are available which are tray fermenters  rotary drum fermenters and fluidized bed fermenters:

Tray fermenters usually using wooden  plastic or metal trays are simple and widely used in traditional SSF. The cultivation is done in stationary trays with no mechanical agitation.

In rotary drum fermenters  the drum rotates intermittently during cultivation to agitate and mix the substrate.

In the fluidized bed fermenter  the solid substrate is fluidized by upward airflow.

Disadvantages of the existing SSF systems
1. There are not many SSF systems on market. Normally they are available as custom-made equipments  meaning that they are only meant for one purpose only.
2. In term of maintenance  the existing SSF systems are rather difficult to maintain  as they have no in situ sterilization systems.
3. Many existing SSF systems are based on shallow tray systems  which make mixing process a difficult if not impossible task.
4. In term of sterility  the existing SSF systems are only sterile at the initial stage and not thereafter.

Disadvantages of submerged fermentation system

1. Microorganisms and substrates
2. Water usage
3. Oxygen supply
4. Volume to fermentation mash
5. Liquid waste produced
6. Physical energy requirement
7. Human energy requirement
8. Capital investment Need to be agitated continuously
Unlimited use
Aeration
Larger
Larger
High
Low
High

Most manufactures are particularly interested in producing submerged fermentation systems. Therefore  a need exits to overcome the need for mass production of microbial metabolites that have industrial potential via SSF.

The present inventors have found that a system (hereinafter referred to as “FERMSOSTAT”) for cultivation and fermentation processes can have the ability to control different fermentation parameters and avoid contamination when uniquely designed fermenters are introduced for appropriate parametric control in the fermentation process.

SUMMARY

Accordingly  one object of the present invention is to overcome the disadvantages/drawbacks of the prior art.

Another object of the present invention is to provide a system having unique design for appropriate control over fermentation parameters and avoid contamination.

Another object of the present invention is to provide a feasible and low cost system for solid state fermentation processes.

Yet another object of the present invention is to provide a low energy consumption and environmental friendly system in the solid state fermentation processes.

Yet another object of the present invention is to provide a system with unique design for a wide range of applications in the solid state fermentation process.

According to one aspect  the present invention relates to a system for use in a solid state fermentation process  said system comprising
(a) a fermenter module having plural port means for allowing inlet and outlet of substrate to be fermented; and
(b) a control module being operatively inter-engaged with said fermenter module in a manner so as to provide control of fermentation parameters.

DETAILED DESCRIPTION

The present invention relates to a system for use in a solid state fermentation (SSF) process. The system comprises a fermenter module which has plural port means for allowing inlet and outlet of substrate to be fermented. The fermenter module comprises a fermenter vessel which accommodates the substrate to be fermented. The fermenter module is operatively inter-engaged with a control means which provide control of fermentation parameters. The fermenter vessel comprises a viewing glass provided over a predetermined superficial area on the surface of the vessel thereby aiding in realizing the current state of the substrate which is undergoing fermentation process inside the vessel.

Another embodiment of the present invention describes plurality of port means operatively engaged to the fermenter vessel. The port means includes substrate port and sampling port where the substrate port is adapted to communicate substrate to be fermented into the fermenter vessel. The biomass and extraction solution flow out through the sampling port.

Another embodiment of the present invention describes a control means in electro-mechanical inter-engagement with the fermenter vessel. The control means is adapted for controlling temperature  agitation rate  stirring frequency  outlets for sampling  inlets for inoculum and substrate addition.

Another embodiment of the present invention describes the fermenter vessel operatively equipped with speed control motor means. The motor means controls the speed of mixing the substrate during solid state fermentation process in the fermenter vessel.

EXAMPLE:

The performance of the system or “FERMSOSTAT” has been evaluated for the production of cellulase and xylanase enzymes by Aspergillus niger USM A1 1. After using the optimized conditions [500 g of substrate (combination of palm kernel cake and sugarcane bagasse at 1:1 ratio)  moisture content of 75%  incubation period for 4 days at 30°C]  about 81 U/g of cellulases and 492 U/g of xylanases were produced  respectively.

The invention has been described in a preferred form only and many variations may be made in the invention which will still be comprised within its spirit. The invention is not limited to the details cited above. The components herein described may be replaced by its technical equivalence and yet the invention can be performed. The structure thus conceived is susceptible of numerous modifications and variations  all the details may furthermore be replaced with elements having technical equivalence. In practice the materials and dimensions may be any according to the requirements  which will still be comprised within its true spirit.

FERMSOSTAT is a portable of SSF unit which can be used for the cultivation and fermentation processes of fungi using solid substrates such as agro-waste materials or domestic wastes. The unit acts as a bioreactor/fermenter for the bioconversion of solid wastes into useful products. The unit is equipped with sets of control system for temperature  agitation speed  mixing/stirring frequency and also outlets for sampling and inlets for inoculum and substrate additions. The FERMSOSTAT is an automatic equipment with one push button system and does not need a technician to operate it.

Advantages of this invention:

1. This invention is new and is not an improvement of any existing product.
2. This invention has been designed to be applicable for a wide range of SSF processes such as the production of enzymes and other microbial metabolites  for the production of flavoring compounds  biomass  animal feeds  compost  antimicrobial compounds and also production of fermentable sugars. It is also applicable for fermentation processes of coffee and cocoa beans  in order to enhance their flavoring properties.
3. This prototype represents an economical  feasible  low cost system  low energy consumption and environmental friendly in the development of SSF processes.

We claim:

1. A system for use in a solid state fermentation process  said system comprising
a fermenter module having plural port means for allowing inlet and outlet of substrate to be fermented; and
a control module being operatively inter-engaged with said fermenter module in a manner so as to provide control of fermentation parameters.

2. A system as claimed in claim 1 wherein said fermenter module comprises a fermenter vessel adapted for accommodating and mixing predetermined volume of the substrate.

3. A system as claimed in claims 1 and 2 wherein said fermenter vessel further comprises viewing glass provided over a predetermined superficial area on the vessel surface in a manner that substrate inside the vessel is visible from outside.

4. A system as claimed in claim 1 wherein said port means comprises a) substrate port and b) sampling port.

5. A system as claimed in claim 4 wherein said substrate port adapted to communicate substrate to be fermented into the fermenter vessel.

6. A system as claimed in claim 4 wherein said sampling port adapted to provide a flow out passage for biomass and extraction solution.

7. A system as claimed in claim 1 wherein said control means being adapted for controlling temperature.

8. A system as claimed in claim 1 wherein said control means being further adapted to control agitation rate.

9. A system as claimed in claim 1 wherein said control means being further adapted to control stirring frequency.

10. A system as claimed in claim 1 wherein said control means being further adapted to control outlets for sampling.

11. A system as claimed in claim 1 wherein said control means being further adapted to control inlets for inoculum and substrate addition.

12. A system as claimed in any one of preceding claims further comprises speed control motor.

13. A system as claimed in any one of preceding claims further comprises spraying nozzle.

14. A system as claimed in any one of preceding claims further comprises impeller.

15. A system as claimed in any one of preceding claims further comprises mixing control panel.

16. A system as claimed in any one of preceding claims further comprises flowmeter.

17. A system as claimed in any of preceding claims adapted for production of microbial metabolites  flavoring compounds  biomass  animal feeds  compost  antimicrobial compounds and/or fermentable sugars and the like.

Dated this 14th day of September  2011

MADHUSUDAN S.T
OF K & S PARTNERS
AGENT FOR THE APPLICANT